Tray

ABSTRACT

A cross-nesting tray provided with means for interlocking an upper second tray in a lower first tray when said upper tray is cross-nested in a like lower tray. If desired, vertically registering stacking means can be provided on the tops of tray walls and in the bottom end portion of said walls to permit stacking a like third tray on said first tray, over said second tray, and cross-nested in said second tray.

United States Patent 1191 Johnson [11] 3,870,151 1451 Mar. 11, 19753,675,815 7/1972 Rehrig 206/507 3,727,791 4/1973 Fraser 220/72 FOREIGNPATENTS OR APPLlCATlONS l,349,646 12/1967 France 206/509 PrimaryExaminer-George E. Lowrance [57] ABSTRACT A cross-nesting tray providedwith means for interlocking an upper second tray in a lower first traywhen said upper tray is cross-nested in a like lower tray. If desired,vertically registering stacking means can be provided on the tops oftray walls and in the bottom end portion of said walls to permitstacking a like third tray on said first tray, over said second tray,and crossnested in said second tray.

14 Claims, 11 Drawing Figures PATENTEDHARI 1 19. 5

.SHEET 0F 4 TRAY This invention relates to a tray.

Trays of various kinds have been widely employed in moving commodities,e.g., foodstuffs, from one location to another. It is highly desirablethat said trays be of a durable, rigid, light weight structure, be easyto handle in use, be easy to store when not in use, be of a simple andinexpensive construction which is easy to manufacture, and be economicalin cost, regardless of size. For example, it is desirable that saidtrays can be stored in stable stacks occupying minimum space when not inuse. Said trays should be easy to clean and, preferably, all surfacesthereof should be self-draining. It is also preferable that said traysbe resistant to collection of foreign matter, e.g., dirt, flour, etc.,in any corners, angles, etc., in the tray structure. Few trays meetingall of the above requirements have been provided by the prior art.

The present invention solves the above-described problems by providingtrays which meet all of the above requirements. The trays of theinvention are cross-nesting trays having a structure which permits saidtrays to be cross-nested and/or stacked in an interlocking mannerwhereby said' trays can be stored or used in stable stacks occupyingminimum space. A feature of at least some preferred embodiments of thetrays of the invention is that all surfaces of the tray structure areself-draining during cleaning. A further feature of said preferredembodiments is that the trays are resistant to the collection of foreignmatter in or on the structure thereof, e.g., at the junctions betweenstructural members. Said last mentioned features are made possible byproviding the tray with a structure wherein the various structuralmembers themselves, and the intersections and other junctions betweensaid structural members of the tray, are provided with curved surfaces.Said curvedsurfaces are resistant to the collection of foreign matterand are self-draining during washing operations.

Thus, according to the invention, there is provided:

A tray comprising:

a pair of upstanding opposed first walls;

a pair of upstanding opposed second walls, having a length greater thansaid first walls, joined to said first walls along the upstanding edgesthereof;

said second walls having a height, substantially along the full lengththereof, which is less than the height of said first walls forpermitting cross-nesting of an upper tray in a like lower tray betweenthe higher first walls thereof;

a bottom panel joined to the lower end portions of said first and saidsecond walls to provide a generally rectangular open top structure; and

a generally flat wall means formed in each end portion of, and recessedinwardly from the outermost face of, each of said second walls forinterlocking FIG. 3 is a side elevation view of the tray of FIG. 1.

FIG. 4 is an end elevation view of the tray of FIG. 1.

FIGS. 5 and 6 are cross section views taken along the lines 55 and 66,respectively, of FIG. 1.

FIGS. 7 and 8 are cross section views taken along the lines 7-7 and 8-8,respectively, of FIG. 2.

1 FIG. 9 is a perspective view showing two trays of the invention instacked relationship.

FIG. 10 is a perspective view showing two trays of the invention incross-nested relationship.

FIG. 11 is a fragmentary plan view illustrating details of one bottomgridwork construction which can be employed in the trays of theinvention.

Referring now to the drawings, wherein like reference numerals areemployed to denote like elements, the invention will be more fullyexplained. In FIG. I there is illustrated a generally rectangular tray10 comprising a pair of upstanding, opposed first or end wall members 12and 12. A pair of upstanding, opposed second or side walls 14 and 14'are disposed transverse to said first walls and are joined, preferablyin a curved junction, along the upstanding edges thereof to the upstanding edges of said first wall members. A bottom member is joined,preferably in an upwardly curved junction, to the lower portions of saidfirst wall members and to the lower portions of said second wall membersto provide a generally rectangular open top structure. If desired, saidbottom member can be a solid member, e.g., no perforations or otheropenings therein. In most instances it is preferred that said bottommember have an open gridwork construction. Any suitable gridworkstructure can be employed, forexample, such as illustrated in Roush etal. US. Pat. No. 3,494,502, issued Feb. 10, I970, Bridenstine US. Pat.No. 3,648,883, issued Mar. 14, I972, or Fraser et al. US Pat. No.3,727,791 issued Apr. 17, 1973. Preferably, said bottom member comprisesa plurality of intersecting grid members which are joined at the endsthereof to said wall members. Preferably, the radius of curvature 18 atthe junctions of said wall members and the radius of curvature 20 at thejunctions of said bottom member(s) with said wall members are at leastone-fourth inch.

It will be noted that said side walls 14 and 14' have a height,substantially along the full length thereof. which is less than theheight of said end walls 12 and 12. The purpose of this structure is forpermitting cross-nesting of an upper tray in a like lower tray betweenthe higher end walls 12 and 12' thereof. Preferably, said height of theside walls 14 and 14' will not be I greater than one-half the height ofsaid end walls 12 said second walls of an upper tray with said first and12'. More preferably, the height of said side walls will be less thanone-half the height of said end walls. A practical range for the heightof said side walls will generally be within the range of from aboutone-third up to less than one-half the height of said end walls.

Said side walls 14 and 14' will have a length greater than said endwalls 12 and 12. Thus, in the trays of the invention, the trays willhave a generally rectangular configuration wherein two sides of therectangle have a length greater than the other two sides of therectangle. The length of said greater length walls, e.g., the sidewalls, will be greater than the length of said end walls by an amountwhich is at least twice the overall wall thickness (including offsets orconvolutions) of the other walls, e.g., the end walls.

Preferably, all the walls of the tray will be formed with offsets orconvolutions therein, e.g., alternately spaced recessed and nonrecessedareas, as illustrated in the drawings, for purposes of increasedstrength. However, it is within the scope of the invention for the wallsof the tray to be essentially straight except for the reeessed,generally flat wall means which is formed in the end portion of each ofthe side walls 14 and 14.

Said generally flat wall means 15 formed in each end portion of, andwhich is recessed inwardly from the outermost face of, each of said sidewalls 14 and 14' is provided for interlocking said side walls of anupper tray with the end walls 12 and 12' ofa lower tray when an uppertray is cross-nested in a like lower tray.

Preferably, said side walls and said end walls are joined together ateach of'the corners of the tray by an upwardly extending corner postsection 17 which preferably has the same height as the end walls. Saidcorner post sections 17 each comprise a portion of the abovedescribedgenerally flat wall means 15 which is formed in each end portion of eachof the side walls, andthus each comprises a portion of a said side wall.Said corner post sections 17 act as a lateral brace, markedly increasingthe strength and rigidity of the end walls.

It will be understood by those skilled in the art in view of thisdisclosure that the width of the tray at said recessed generally flatwall means 15, and the length of the tray between the portions of theend walls 12 and 12 adjacent thereto (or the distance between theupstanding edges of corner post sections 17 when said corner postsections are employed), are dimensioned so that said flat wall means 15will fit between said end walls (or said corner post sections) in aninterlocking manner. Preferably, the length of said flat wall means 15will be dimensioned so as to provide an interlocking fit between theshoulder 16 formed at the end of the nonrecessed portion of the sidewalls 14 and 14 and said end walls (or said corner post sections). SeeFIG. 10.

Referring to FIG. 10, it is clear therefrom that a third like tray canbe stacked on the end walls 12 and 12 of the bottom or first tray, andover a second or upper tray, when the side walls 14 and 14 of the trayshave a height which is not greater than the height of the end walls 12and 12' of the trays, and that said third tray will be cross-nestedbetween corner posts 17 of said second tray. In this manner, trays ofthe invention can be alternately cross-nested and stacked to anyreasonably desired height to give a stable stack, such as for storagewhen not in use.

In the preferred embodiments of the invention, vertically registeringstacking means are provided on the top of, and in the bottom end portionof, each of the end walls. Said vertically registering stacking meanscan comprise any suitable stacking means known to the art. For example,a generally V-shaped crown on the top of said walls, and acorrespondingly shaped groove in the bottom of said walls. Asillustrated in the drawings, the stacking means provided on the top ofeach of the end walls can simply comprise a generally flat surfaceextending generally along the top of said end walls. Also, asillustrated in FIGS. 5 and 6, the stacking means provided in the bottomend portion of each of the end walls can comprise an inwardly andgenerally horizontally extending shoulder 19 formed in said bottom endportion. Preferably, each of said shoulders will have'a downwardlyextending inner face means or leg 21 which is contiguous with thehorizontally extending portion thereof for engaging the upper inner wallsurfaces of the end walls 12 and 12' (and the corner post sections 17when provided) when an upper tray is stacked on a lower tray. In thismanner, said upper tray and said lower tray will be further interlockedagainst both longitudinal and transverse movement. See FIG. 9.

If desired, each of said walls 12, 12, I4, and 14' can be provided withat least one drainage opening 54 therein with the bottom of said openingbeing essentially flush with the upper surface of the bottom panel ofthe tray. Said openings provide improved drainage during washing of thetrays, particularly when the trays are tilted at an angle. If desired,said openings can extend around the corners of the tray, as shown. Ahandhold opening 56 is preferably provided in each of end walls 12 and12'.

In one preferred embodiment, said gridwork bottom can comprise a firstplurality of grid members 34 which are disposed generally parallel tosaid first or end wall members 12 and 12', are spaced apart from eachother, and extend between said pair of second or side wall members 14and 14'. A second plurality of grid members 36 are disposed generallyparallel to said second or side wall members 14 and 14, are spaced apartfrom each other, and extend between said pair of first or side wallmembers 12 and 12'. Said second grid members 36 are disposed generallyparallel to said side wall members in an intersecting direction withrespect to said first grid members 34 so as to form ajunction therewithand form a plurality of rectangles arranged in rows generally parallelwith said wall members. Said wall members form one side of the outerrows of said rectangles. A curved fillet 38 is preferably providedbetween each pair of adjacent grid members at said junction of said gridmembers. The radius of curvature of said fillet 38 is preferably atleast one-fourth inch. This structure is illustrated in FIG. 11.

In one presently preferred embodiment of the invention, said gridworkbottom member can further comprise a third plurality of grid members 40.Each one of said third grid members 40 extends substantially diagonallyacross one of each of said rectangles and is joined to said first andsecond grid members at said junction thereof to form junctions of saidfirst, second, and third grid members. A fourth plurality of gridmembers 42 is also provided. Each one of said grid members 42 extendssubstantially diagonally across one of each of said rectangles in adirection to integrally intersect said diagonally extending grid members40 at approximately the center of the rectangle and is joined to saidfirst and second grid members at said junctions thereof to formjunctions of said first, second, and fourth grid members. Preferably,fillets 38 are provided between each pair of adjacent grid members atall of said junctions. In each rectangle of said outer rows ofrectangles there is provided a grid member 44 which extends from theintersection of said diagonally extending grid members 40 and 42 to oneof said wall members. Preferably. a fillet 38 is also provided at thejunction of said grid member 44 with wall 14 and the intersection ofsaid diagonally extending grid members 40 and 42.

Said junctions of said first, second, and fourth grid members, togetherwith said junctions of said first, second, and third grid members, forma reinforcing island. Preferably, an opening 48 is provided in saidisland as illustrated in FIG. 1. Preferably, the radius of curvature ofthe curved portions of said opening is at least onefourth inch. Saidopenings are preferably generally oval in shape, as illustrated.However, said opening can have a round, elliptical, or other generallycurved shape.

FIG. 2 is a view of a presently preferred structure of the underside ofthe tray of FIG. 1. If desired, each of the grid members 34, 36, 40, 42,and 44 can be provided with a downwardly extending rib 50 as shown inFIGS. 5 and 7 to give the grid members a generally T- shape and provideadditional strength. The junction of the vertical rib 50 with the bar ofthe T is preferably provided with a fillet 38. Where not needed forstrength, the vertical rib 50 can be omitted as shown by referencenumeral 52 in FIG. 8 and the grid member will have a flat ribbon-likeconfiguration. In FIG. 2 the vertical rib 50 has also been omitted fromgrid members 40 and 42 except for those of said members 40 and 42 whichextend in a diagonal direction between the corners of the tray.

If desired, in all the above-described embodiments of the invention,said gridwork bottom can be coved upwardly a small distance, e.g.,one-sixteenth to threesixteenths inch, from the outer edge toward thecenter of the tray. This will provide increased accommodation forheavier loads, i.e., without causing the bottom to sag. Preferably, asshown in FIGS. 5 and 7, the bottom portion of the grid members which areprovided with a downwardly extending vertical rib 50 are curved so as toprovide better self-draining properties. Preferably, the bottom portionof said wall members is also similarly curved, as shown in said FIGS. 5and 6.

Trays fabricated in accordance with the invention possess a number ofadvantageous features over trays of the prior art. The curved surfaceswhich are preferably provided at the junctions of the various structuralelements of the tray, and elsewhere, render the tray resistant to theaccumulation of foreign materials such as flour. icings, jelly, etc.,during use. Said curved surfaces also render the trays self-draining inessentially any position, even inverted, during washingor other cleaningoperations. Said curved surfaces will have a radius of curvaturesufficient to provide these advantageous features. A radius of curvatureof at least one-fourth inch for said curved surfaces, while notessential in all instances, is preferred in order to insure obtainingsaid advantageous features. The trays of the invention are of a durable,lightweight structure. This is an important consideration in the use ofsaid trays. For example, said trays are particularly well adapted fortransporting bakery goods, both within the baking shop and the deliverytruck. The bakery goods can be placed on the trays and the trays thenplaced in racks which may be easily pushed around the shop. The trayscan also be readily loaded onto racks in a delivery truck. The lightweight of the trays is a distinct advantage in that handling of thetrays is not only less tiring for personnel handling same but alsoreduces the load on trucks. Thus, lighter weight trucks can be employedwith obvious savings in operating expenses.

The trays of the invention can be fabricated in any suitable mannerknown to the art. Injection molding, for example, is one presentlypreferred method for fabricating said trays. Said trays can befabricated from any suitable material. High density polyethylenes areespecially desirable materials from which to fabricate said trays. Thehigh density polyethylenes prepared by the methods disclosed and claimedby .I. P. Hogan et al. in US. Pat. No. 2,825,721, issued Mar. 4, 1958,are one group of presently preferred materials. Said trays can also befabricated from butadiene-styrene copolymers, and other plasticmaterials. If desired, a reinforcing fibrous material, such as asbestosor glass fibers, can be incorporated in the plastic material. While thevarious plastics are presently preferred for the manufacture of thetrays, it is within the scope of the invention to fabricate said traysfrom other materials, e.g., lightweight metals such as aluminum,reinforced pulp materials, etc.

As an illustration, one model of a tray in accordance with the inventionhas an overall length of about 24.5 inches and an overall width of about22.5 inches. The rectangles in the gridwork bottom are about 3.3 X 3.0inches, the top surface of the bottom grid members are about 0.25 inchwide, the end walls 12 and 12' and corner posts 17 are about 5.1 inchesin height, and the side walls 14 and 14' are about 2.25 inches inheight. The width at recessed wall means 15 is about 21.94 inches andthe distance between corner post sections I7 (see FIG. 3) is about 22.06inches. The remainder of the elements of the tray are generallyproportional in size. These dimensions are given by way of illustrationonly, are not to be construed as limiting on the invention in any way,and all can be varied within the scope of the invention.

While certain embodiments of the invention have been described forillustrative purposes, the invention is not limited thereto. Variousother modifications or embodiments of the invention will be apparent tothose skilled in the art in view of this disclosure. Such modificationsor embodiments are within the spirit and scope of the disclosure.

I claim:

I. A tray comprising:

a pair of upstanding opposed first walls;

a pair of upstanding opposed second walls, having a length greater thansaid first walls, joined to said first walls along the upstanding edgesthereof;

said second walls having a height, substantially along the full lengththereof, which is less than the height of said first walls forpermitting cross-nesting of an upper tray in a like lower tray betweenthe higher first walls thereof;

a bottom panel joined to the lower end portions of said first and saidsecond walls to provide a generally rectangular open top structure;

a generally flat wall means formed in each end portion of, and recessedinwardly from a nonrecessed portion of, each of said second walls; and

an outwardly extending shoulder formed in each of said second walls ateach junction of a said fiat wall means and a said nonrecessed portionof said second walls for, together with said flat wall means,interlocking said second walls of an upper tray with said first walls ofa like lower tray when an upper tray is cross-nested in a like lowertray.

2. A tray according to claim 1 wherein each of said second walls has aheight which is not greater than onehalf the height of said first walls.

3. A tray according to claim 1 wherein each of said second walls has aheight which is less than one-half the height of said first walls.

4. A tray according to claim 2 wherein vertically registering stackingmeans are provided on the top of, and in the bottom end portion of, eachof said first walls.

5. A tray according to claim 4 wherein said stacking means provided inthe bottom end portion of each of said first walls comprises an inwardlyand generally horizontally extending shoulder formed in said bottom endportion.

6. A tray according to claim 2 wherein a portion of each of saidgenerally flat wall means formed in each end portion of each of saidsecond walls comprises a corner post section having the same height assaid first walls.

7. A tray according to claim 6 wherein vertically registering stackingmeans are provided on the top of each of said first walls, on the top ofeach said corner post sections, in the bottom end portion of each ofsaid first walls, and in the bottom end portion of each of said cornerpost sections.

8. A tray according to claim 7 wherein:

said stacking means provided on the top of each of said first walls andon the top of each said corner post section comprises a generally flatsurface extending generally along the top of said first walls and thetop of said corner post sections; and

said stacking means provided in the bottom end portion of each of saidfirst walls and in the bottom end portion of each of said corner postsections comprises an inwardly and generally horizontally extendingshoulder formed in said bottom end portions.

9. A tray according to claim 8 wherein:

each of said shoulders has a downwardly extending inner face meanscontiguous with the horizontally extending portion thereof for engagingthe upper drainage opening is provided in each of said first and saidsecond walls with the bottom of said opening being essentially flushwith the upper surface of said bottom panel.

11. A tray according to claim 2 wherein said bottom panel is of opengridwork construction.

12. A tray according to claim I] wherein:

said open gridwork construction comprises a plurality of intersectinggrid members joined at the ends thereof to said walls in an upwardlycurved junction; and

a curved fillet is provided between each pair of adjacent grid membersat the intersections of said grid members.

13. A tray according to claim 9 wherein at least one drainage opening isprovided in each of said first and said second walls with the bottom ofsaid opening being essentially flush with the upper surface of saidbottom panel.

14. A tray according to claim 13 wherein:

said bottom panel is of an open gridwork construction comprising aplurality of intersecting grid members joined at the ends thereof tosaid walls in an upwardly curved junction; and

a curved fillet is provided between each pair of adjacent grid membersat the intersections of said grid members.

1. A tray comprising: a pair of upstanding opposed first walls; a pairof upstanding opposed second walls, having a length greater than saidfirst walls, joined to said first walls along the upstanding edgesthereof; said second walls having a height, substantially along the fulllength thereof, which is less than the height of said first walls forpermitting cross-nesting of an upper tray in a like lower tray betweenthe higher first walls thereof; a bottom panel joined to the lower endportions of said first and said second walls to provide a generallyrectangular open top structure; a generally flat wall means formed ineach end portion of, and recessed inwardly from a nonrecessed portionof, each of said second walls; and an outwardly extending shoulderformed in each of said second walls at each junction of a said flat wallmeans and a said nonrecessed portion of said second walls for, togetherwith said flat wall means, interlocking said second walls of an uppertray with said first walls of a like lower tray when an upper tray iscross-nested in a like lower tray.
 1. A tray comprising: a pair ofupstanding opposed first walls; a pair of upstanding opposed secondwalls, having a length greater than said first walls, joined to saidfirst walls along the upstanding edges thereof; said second walls havinga height, substantially along the full length thereof, which is lessthan the height of said first walls for permitting cross-nesting of anupper tray in a like lower tray between the higher first walls thereof;a bottom panel joined to the lower end portions of said first and saidsecond walls to provide a generally rectangular open top structure; agenerally flat wall means formed in each end portion of, and recessedinwardly from a nonrecessed portion of, each of said second walls; andan outwardly extending shoulder formed in each of said second walls ateach junction of a said flat wall means and a said nonrecessed portionof said second walls for, together with said flat wall means,interlocking said second walls of an upper tray with said first walls ofa like lower tray when an upper tray is cross-nested in a like lowertray.
 2. A tray according to claim 1 wherein each of said second wallshas a height which is not greater than one-half the height of said firstwalls.
 3. A tray according to claim 1 wherein each of said second wallshas a height which is less than one-half the height of said first walls.4. A tray according to claim 2 wherein vertically registering stackingmeans are provided on the top of, and in the bottom end portion of, eachof said first walls.
 5. A tray according to claim 4 wherein saidstacking means provided in the bottom end portion of each of said firstwalls comprises an inwardly and generally horizontally extendingshoulder formed in said bottom end portion.
 6. A tray according to claim2 wherein a portion of each of said generally flat wall means formed ineach end portion of each of said second walls comprises a corner postsection having the same height as said first walls.
 7. A tray accordingto claim 6 wherein vertically registering stacking means are provided onthe top of each of said first walls, on the top of each said corner postsections, in the bottom end portion of each of said first walls, and inthe bottom end portion of each of said corner post sections.
 8. A trayaccording to claim 7 wherein: said stacking means provided on the top ofeach of said first walls and on the top of each said corner post sectioncomprises a generally flat surface extending generally along the top ofsaid first walls and the top of said corner post sections; and saidstacking means provided in the bottom end portion of each of said firstwalls and in the bottom end portion of each of said corner post sectionscomprises an inwardly and generally horizontally extending shoulderformed in said bottom end portions.
 9. A tray according to claim 8wherein: each of said shoulders has a downwardly extending inner facemeans contiguous with the horizontally extending portion thereof forengaging the upper inner wall surfaces of said first walls and saidcorner post sections when an upper tray is stacked on a lower traywhereby said upper tray and said lower tray are interlocked against bothlongitudinal and transverse movement.
 10. A tray according to claim 2wherein at least one drainage opening is provided in each of said firstand Said second walls with the bottom of said opening being essentiallyflush with the upper surface of said bottom panel.
 11. A tray accordingto claim 2 wherein said bottom panel is of open gridwork construction.12. A tray according to claim 11 wherein: said open gridworkconstruction comprises a plurality of intersecting grid members joinedat the ends thereof to said walls in an upwardly curved junction; and acurved fillet is provided between each pair of adjacent grid members atthe intersections of said grid members.
 13. A tray according to claim 9wherein at least one drainage opening is provided in each of said firstand said second walls with the bottom of said opening being essentiallyflush with the upper surface of said bottom panel.